A hydrogen compressor cycle test system

Abstract

This utility model discloses a hydrogen compressor cycle testing system, including a test gas source system, a gas pressurization and recovery system, and a closed-loop system. The test gas source system provides test gas through a gas storage cylinder, which is purified by a pneumatic control valve and a filter before being input into the system. The gas pressurization and recovery system uses a high-pressure pneumatic booster pump to pressurize the gas to 125 MPa through a booster circuit and store it in a high-pressure storage tank. Simultaneously, the gas is recovered in a closed loop through a recovery circuit via a pneumatic valve and a check valve. The closed-loop system integrates an electronically controlled proportional pressure reducing valve and a back pressure valve, using PID closed-loop control to regulate the inlet / outlet pressure of the hydrogen compressor, simulating full-condition operation. This utility model solves the problems of serious gas waste, single-condition simulation, and low efficiency in traditional testing systems, possessing comprehensive advantages such as high gas recovery rate, accurate simulation of multiple operating conditions, short testing cycle, and comprehensive safety protection.

Description

Technical Field

[0001] This utility model relates to the field of compressor technology, specifically a hydrogen compressor cycle testing system. Background Technology

[0002] Hydrogen energy has enormous application potential in energy storage and utilization, contributing to the formation of a diversified and complementary modern energy system. As a secondary energy source, hydrogen can be used for large-scale, long-term, and cross-seasonal energy storage, improving the flexibility of power system regulation. High-pressure gaseous hydrogen storage is a common hydrogen energy storage method, easily achieved through high-pressure hydrogen compressors. High-pressure hydrogen compressors are commonly used in hydrogen refueling stations, serving as one of their three core pieces of equipment. During operation, they need to adapt to different inlet and outlet pressures. Currently, most hydrogen compressors lack continuous performance testing under different operating conditions, and their performance indicators, the lifespan of vulnerable parts, and reliability have not been fully verified. Consequently, various problems frequently arise during commercial use.

[0003] Meanwhile, hydrogen is a flammable, explosive, and easily leaked gas. Therefore, the safety of testing hydrogen compressors, which serve as hydrogen pressurization devices, is paramount. Consequently, all performance tests of the compressor are conducted first using inert gases, followed by hydrogen testing. Currently, hydrogen compressor testing involves drawing gas from a storage tank, pressurizing it using the hydrogen compressor, and then releasing the gas through a venting pipe after the test. This process requires frequent start-ups and shutdowns of the hydrogen compressor and the venting of the test gas after each test, resulting in high gas consumption and costs. Helium, in particular, is an ideal test gas for hydrogen compressor testing due to its similar physical properties to hydrogen, but its high price is a significant burden on compressor testing. Utility Model Content

[0004] The purpose of this invention is to provide a hydrogen compressor cycle testing system that achieves gas recovery through a closed-loop design and uses an electronically controlled proportional valve to simulate various working conditions, thereby solving the problems of high testing cost and low efficiency in the existing technology.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a hydrogen compressor cycle test system, including a test gas source system, a gas pressurization and recovery system, a closed-loop system, a cooling system, a control system, and a hydrogen compressor to be tested;

[0006] The test gas source system includes a gas storage cylinder, a pneumatic control valve, a check valve, a filter, and a pressure gauge. The gas storage cylinder is connected to the pneumatic control valve, the check valve, the filter, and the pressure gauge in sequence through a high-pressure rigid pipe to provide test gas to the system.

[0007] The gas pressurization and recovery system includes a gas booster pump, a high-pressure gas storage tank, a heat exchanger, a control valve, a safety valve, a pneumatic control valve, and a check valve. The inlet of the gas booster pump is connected to the filter of the test gas source system via a high-pressure rigid pipe, and the outlet is sequentially connected to the heat exchanger, the high-pressure gas storage tank, the control valve, and the safety valve, and is connected to a closed-loop system via the control valve. The gas recovery circuit recovers the test gas to the gas storage cylinder via the pneumatic control valve and the check valve.

[0008] The closed-loop system includes an inlet buffer tank, an exhaust buffer tank, an electronically controlled proportional pressure reducing valve, an electronically controlled proportional back pressure valve, a gas flow meter, and multiple control valves. The inlet buffer tank is connected to the control valves of the gas pressurization and recovery system via a high-pressure hard pipe, and is sequentially connected to the electronically controlled proportional pressure reducing valve and the inlet of the hydrogen compressor under test. The exhaust port of the hydrogen compressor under test is sequentially connected to the electronically controlled proportional back pressure valve, the exhaust buffer tank, and the gas flow meter via a high-pressure hard pipe, forming a closed-loop circuit.

[0009] The cooling system is connected to the heat exchanger of the hydrogen compressor and the heat exchanger of the closed-loop system via low-pressure hoses.

[0010] The control system uses a PLC control unit, which is electrically connected to the gas booster pump, various pneumatic control valves, and electronically controlled proportional valves, and is used to adjust the intake pressure, exhaust pressure and gas recovery process in real time.

[0011] Preferably, the gas booster pump is a high-pressure pneumatic booster pump with a booster ratio ≥150 and a maximum discharge pressure of 125MPa; the electronically controlled proportional pressure reducing valve and the electronically controlled proportional back pressure valve both integrate PID control units and achieve closed-loop control through feedback signals from the pressure transmitter.

[0012] Preferably, the intake buffer tank and the exhaust buffer tank are each equipped with a safety valve and are isolated from the closed-loop circuit through a control valve; the safety valve of the high-pressure gas storage tank is connected to the circuit through the control valve.

[0013] Preferably, the gas flow meter parallel control valve in the closed-loop system is used to isolate or switch the flow meter operating conditions.

[0014] Preferably, the cooling system uses an air-cooled chiller unit to provide circulating cooling water for the heat exchanger.

[0015] Preferably, the control system simulates various operating conditions of the hydrogen compressor in the range of 45MPa to 90MPa by adjusting the electronically controlled proportional pressure reducing valve and the electronically controlled proportional back pressure valve.

[0016] The working process of this utility model is as follows:

[0017] (1) System startup and initialization

[0018] Test gas supply: Open the pneumatic control valve, and the test gas, such as helium or hydrogen, enters the system from the gas storage cylinder after being purified by a one-way valve and a filter.

[0019] Pressure and temperature calibration: The initial parameters are monitored by pressure gauges and temperature gauges, and the control system PLC initializes the set values ​​of the electronically controlled proportional pressure reducing valve and back pressure valve.

[0020] (2) Gas pressurization and pressure resistance test

[0021] Pressurization phase: Start the gas booster pump to pressurize the test gas to the target pressure, such as 45MPa or 90MPa. After pressurization, the gas is cooled by a heat exchanger and stored in a high-pressure gas storage tank.

[0022] Pressure resistance test: Close some control valves of the closed-loop system, introduce high-pressure gas into the hydrogen compressor under test, seal the compressor outlet, and monitor the system's pressure resistance performance through pressure gauges and safety valves to verify the compressor's sealing performance and pressure resistance.

[0023] (3) Closed-loop and operating condition simulation

[0024] Inlet pressure regulation: The electronically controlled proportional pressure reducing valve uses PID closed-loop control to precisely regulate the compressor intake pressure according to a set value, such as 20MPa, and the pressure transmitter provides real-time feedback data.

[0025] Exhaust back pressure simulation: The electronically controlled proportional back pressure valve sets the compressor exhaust pressure to 90MPa, and combined with the exhaust buffer tank and heat exchanger to stabilize the gas temperature, simulating the actual high-pressure working conditions.

[0026] Performance monitoring: Gas flow meters record flow rate in real time, and temperature and pressure sensors collect data to evaluate compressor energy efficiency, temperature rise, and stability.

[0027] (4) Gas recovery and system unloading

[0028] Recovery Start-up: After the test is completed, close the booster circuit control valve, open the recovery circuit pneumatic valve, start the gas booster pump to run in reverse, and return the gas in the closed circulation system to the storage cylinder through the check valve.

[0029] Pressure relief: The system pressure is gradually reduced through the second pressure regulating valve to avoid hydraulic shock, and finally the control system closes all valves and the system returns to standby state.

[0030] The beneficial effects of this utility model are as follows:

[0031] (1) Through the closed-loop design of the gas pressurization and recovery system, the gas (such as helium or hydrogen) after testing can be recompressed by the pressurization pump and returned to the storage cylinder, avoiding direct discharge and waste, significantly reducing the consumption cost of high-priced gases, and is especially suitable for the cyclic testing of expensive test gases such as helium.

[0032] (2) The present invention integrates an electronically controlled proportional pressure reducing valve and an electronically controlled proportional back pressure valve. Combined with the closed-loop control of the system, it can dynamically adjust the inlet pressure (e.g., 20MPa to 45MPa) and outlet pressure (e.g., 45MPa to 90MPa) of the hydrogen compressor, accurately simulate various extreme working conditions in actual operation, and comprehensively verify the performance indicators and reliability of the compressor.

[0033] (3) This utility model adopts a modular design, integrating pressure resistance test, cycle performance test and gas recovery functions into the same system, reducing the time spent on equipment disassembly and testing process; at the same time, through safety valve, buffer tank and PLC automatic control, pressure, temperature and flow parameters are monitored in real time, effectively preventing safety hazards such as overpressure and leakage, and ensuring that the testing process is safe and controllable. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the system structure of this utility model;

[0035] In the diagram: 1. Test gas source system; 2. Gas pressurization and recovery system; 3. Closed-loop system; 4. Cooling system; 5. Control system; 6. Hydrogen compressor under test; V01 Gas storage tank; V02 High-pressure storage tank; V03 Inlet buffer tank; V04 Exhaust buffer tank; PDV01 Pneumatic control valve; PDV02 Pneumatic control valve; PDV03 Pneumatic control valve; PDV04 Pneumatic control valve; PDV11 Pneumatic control valve; PDV12 Pneumatic control valve; PDV13 Pneumatic control valve; CV01 Check valve; CV02 Check valve; CV03 Check valve; FEN01 Filter; PP01 Gas booster pump; PI01 Pressure gauges; PI02 pressure gauge; PI11 pressure gauge; PI12 pressure gauge; TI11 temperature gauge; TI12 temperature gauge; C01 heat exchanger; C02 heat exchanger; C03 heat exchanger; PSV01 safety valve; PSV02 safety valve; PSV03 safety valve; PT11 pressure transmitter; PT12 pressure transmitter; PRV01 electrically controlled proportional pressure reducing valve; PRV02 electrically controlled proportional back pressure valve; NV01 control valve; NV02 control valve; NV11 control valve; NV12 control valve; NV13 control valve; NV14 control valve; NV15 control valve; NV16 control valve; NV17 control valve; NV18 control valve. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings.

[0037] like Figure 1 The hydrogen compressor cycle test system shown includes a test gas source system 1, a gas pressurization and recovery system 2, a closed-loop system 3, a cooling system 4, a control system 5, and a hydrogen compressor under test 6.

[0038] The test gas source system 1 includes a gas storage cylinder V01, a pneumatic control valve PDV01, a check valve CV01, a filter FEN01, and a pressure gauge PI01. The gas storage cylinder V01 is connected to the pneumatic control valve PDV01, the check valve CV01, the filter FEN01, and the pressure gauge PI01 in sequence through a high-pressure rigid pipe, which is used to supply test gas to the system.

[0039] The gas pressurization and recovery system 2 includes a gas booster pump PP01, a high-pressure gas storage tank V02, a heat exchanger C01, control valves NV01 and NV02, a safety valve PSV01, a pneumatic control valve PDV03 and PDV04, and a check valve CV02. The inlet of the gas booster pump PP01 is connected to the filter FEN01 of the test gas source system 1 through a high-pressure rigid pipe, and the outlet is connected in sequence to the heat exchanger C01, the high-pressure gas storage tank V02, the control valve NV01, and the safety valve PSV01, and is connected to the closed-loop system 3 through the control valve NV02. The gas recovery circuit recovers the test gas to the gas storage cylinder V01 through the pneumatic control valve PDV02 and the check valve CV02.

[0040] The closed-loop system 3 includes an inlet buffer tank V03, an exhaust buffer tank V04, an electronically controlled proportional pressure reducing valve PRV01, an electronically controlled proportional back pressure valve PRV02, a gas flow meter FT01, and multiple control valves. The inlet buffer tank V03 is connected to the control valve NV02 of the gas pressurization and recovery system 2 via a high-pressure hard pipe, and is sequentially connected to the electronically controlled proportional pressure reducing valve PRV01 and the inlet of the hydrogen compressor 6 under test. The exhaust port of the hydrogen compressor 6 under test is sequentially connected to the electronically controlled proportional back pressure valve PRV02, the exhaust buffer tank V04, and the gas flow meter FT01 via a high-pressure hard pipe, forming a closed-loop circuit. The gas flow meter FT01 of the closed-loop system 3 is connected in parallel with control valves NV15, NV16, and NV17 to isolate or switch the flow meter's operating conditions.

[0041] The cooling system 4 is connected to the heat exchanger CO3 of the hydrogen compressor and the heat exchangers CO1 and CO2 of the closed-loop system 3 via low-pressure hoses. The cooling system 4 adopts an air-cooled chiller unit to provide circulating cooling water for the heat exchangers CO1, CO2 and CO3.

[0042] Control system 5 employs a PLC control unit, electrically connected to the gas booster pump PP01, various pneumatic control valves, and electronically controlled proportional valves PRV01 and PRV02, for real-time adjustment of inlet and outlet pressures and the gas recovery process. Control system 5 simulates various operating conditions of the hydrogen compressor within the range of 45MPa to 90MPa by adjusting the electronically controlled proportional pressure reducing valve PRV01 and the electronically controlled proportional back pressure valve PRV02.

[0043] The gas booster pump PP01 is a high-pressure pneumatic booster pump with a boost ratio ≥150 and a maximum discharge pressure of 125MPa. The electronically controlled proportional pressure reducing valve PRV01 and the electronically controlled proportional back pressure valve PRV02 both integrate PID control units and achieve closed-loop control through feedback signals from pressure transmitters PT11 and PT12.

[0044] The intake buffer tank V03 and the exhaust buffer tank V04 are respectively equipped with safety valves PSV02 and PSV03, and are isolated from the closed-loop circuit through control valves NV11 and NV18; the safety valve PSV01 of the high-pressure gas storage tank V02 is connected to the circuit through control valve NV01.

[0045] The working process of this utility model is as follows:

[0046] (1) System startup and initialization

[0047] Test gas supply: Open the pneumatic control valve PDV01, and the test gas, such as helium or hydrogen, enters the system from the gas storage cylinder V01 after being purified by the one-way valve CV01 and the filter FEN01.

[0048] Pressure and temperature calibration: The initial parameters are monitored by pressure gauge PI01 and temperature gauge TI11 / TI12, and the control system PLC initializes the set values ​​of the electronically controlled proportional pressure reducing valve PRV01 and back pressure valve PRV02.

[0049] (2) Gas pressurization and pressure resistance test

[0050] Pressurization stage: Start the gas booster pump PP01 to pressurize the test gas to the target pressure, such as 45MPa or 90MPa. After pressurization, the gas is cooled by the heat exchanger C01 and stored in the high-pressure gas storage tank V02.

[0051] Pressure resistance test: Close some control valves of the closed-loop system, such as NV12 and NV13, and introduce high-pressure gas into the hydrogen compressor 6 under test. Seal the compressor outlet and monitor the system's pressure resistance performance through pressure gauges PI11 and PI12 and safety valves PSV02 and PSV03 to verify the compressor's sealing performance and pressure resistance.

[0052] (3) Closed-loop and operating condition simulation

[0053] Inlet pressure regulation: The electronically controlled proportional pressure reducing valve PRV01 uses PID closed-loop control to precisely regulate the compressor intake pressure according to a set value, such as 20MPa, and the pressure transmitter PT11 provides real-time feedback data.

[0054] Exhaust back pressure simulation: The electronically controlled proportional back pressure valve PRV02 sets the compressor exhaust pressure to 90MPa, and combines it with the exhaust buffer tank V04 and heat exchanger CO2 to stabilize the gas temperature, simulating the actual high-pressure working conditions.

[0055] Performance monitoring: The gas flow meter FT01 records the flow rate in real time, and the temperature and pressure sensors TI11 / TI12 and PI11 / PI12 collect data to evaluate the compressor's energy efficiency, temperature rise, and stability.

[0056] (4) Gas recovery and system unloading

[0057] Recovery Start-up: After the test is completed, close the booster circuit control valve NV02, open the recovery circuit pneumatic valves PDV02 and PDV04, start the gas booster pump PP01 to run in reverse, and return the gas in the closed circulation system to the gas storage cylinder V01 through the one-way valve CV02.

[0058] Pressure relief: The system pressure is gradually reduced through the second pressure regulating valve 9 to avoid hydraulic shock, and finally the control system closes all valves and the system returns to standby state.

[0059] The above are merely preferred embodiments of this utility model. It should be noted that, for those skilled in the art, based on the technical teachings provided by this utility model and as common knowledge in the field, other equivalent modifications and improvements can be made, and these should also be considered within the protection scope of this utility model.

Claims

1. A hydrogen compressor cycle testing system, characterized in that: It includes a test gas source system (1), a gas pressurization and recovery system (2), a closed-loop system (3), a cooling system (4), a control system (5), and a hydrogen compressor to be tested (6). The test gas source system (1) includes a gas storage cylinder V01, a pneumatic control valve PDV01, a check valve CV01, a filter FEN01 and a pressure gauge PI01. The gas storage cylinder V01 is connected to the pneumatic control valve PDV01, the check valve CV01, the filter FEN01 and the pressure gauge PI01 in sequence through a high-pressure hard pipe, which is used to supply test gas to the system. The gas pressurization and recovery system (2) includes a gas pressurization pump PP01, a high-pressure gas storage tank V02, a heat exchanger C01, a control valve NV01, a control valve NV02, a safety valve PSV01, a pneumatic control valve PDV03, a pneumatic control valve PDV04, and a check valve CV02. The inlet end of the gas pressurization pump PP01 is connected to the filter FEN01 of the test gas source system (1) through a high-pressure hard pipe, and the outlet end is connected to the heat exchanger C01, the high-pressure gas storage tank V02, the control valve NV01, and the safety valve PSV01 in sequence, and is connected to the closed-loop system (3) through the control valve NV02. The gas recovery circuit recovers the test gas to the gas storage cylinder V01 through the pneumatic control valve PDV02 and the check valve CV02. The closed-loop system (3) includes an inlet buffer tank V03, an exhaust buffer tank V04, an electronically controlled proportional pressure reducing valve PRV01, an electronically controlled proportional back pressure valve PRV02, a gas flow meter FT01, and multiple control valves. The inlet buffer tank V03 is connected to the control valve NV02 of the gas pressurization and recovery system 2 via a high-pressure hard pipe, and is sequentially connected to the electronically controlled proportional pressure reducing valve PRV01 and the inlet of the hydrogen compressor (6) under test. The exhaust port of the hydrogen compressor (6) under test is sequentially connected to the electronically controlled proportional back pressure valve PRV02, the exhaust buffer tank V04, and the gas flow meter FT01 via a high-pressure hard pipe, forming a closed-loop circuit. The cooling system (4) is connected to the heat exchanger CO3 of the hydrogen compressor and the heat exchangers CO1 and CO2 of the closed-loop system (3) respectively through low-pressure hoses. The control system (5) adopts a PLC control unit, which is electrically connected to the gas booster pump PP01, each pneumatic control valve, and the electronically controlled proportional valves PRV01 and PRV02, and is used to adjust the intake pressure, exhaust pressure and gas recovery process in real time.

2. The hydrogen compressor cycle testing system according to claim 1, characterized in that: The gas booster pump PP01 is a high-pressure pneumatic booster pump with a boost ratio ≥150 and a maximum discharge pressure of 125MPa; the electronically controlled proportional pressure reducing valve PRV01 and the electronically controlled proportional back pressure valve PRV02 both integrate PID control units and achieve closed-loop control through feedback signals from pressure transmitters PT11 and PT12.

3. A hydrogen compressor cycle testing system according to claim 1 or 2, characterized in that: The intake buffer tank V03 and the exhaust buffer tank V04 are respectively equipped with safety valves PSV02 and PSV03, and are isolated from the closed-loop circuit through control valves NV11 and NV18; the safety valve PSV01 of the high-pressure gas storage tank V02 is connected to the circuit through control valve NV01.

4. The hydrogen compressor cycle testing system according to claim 3, characterized in that: The gas flow meter FT01 of the closed-loop system (3) is connected in parallel with control valves NV15, NV16, and NV17 to isolate or switch the operating conditions of the flow meter.

5. A hydrogen compressor cycle testing system according to claim 4, characterized in that: The cooling system (4) adopts an air-cooled chiller unit to provide circulating cooling water for heat exchangers CO1, CO2 and CO3.

6. A hydrogen compressor cycle testing system according to claim 5, characterized in that: The control system (5) simulates various operating conditions of the hydrogen compressor in the range of 45MPa to 90MPa by adjusting the electronically controlled proportional pressure reducing valve PRV01 and the electronically controlled proportional back pressure valve PRV02.

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